Printed planar radio frequency identification elements

ABSTRACT

Each printed sheet product includes a core of flexible, microvoided polymer sheet material and a planar RFID assembly encoded with a unique electro/magnetic code permanently and integrally joined together with the core. The microvoided sheet material collapses around the core so the sheet product remains planar. Scoring defines one or more individual identification elements removable from a remainder of the sheet product that include at least a first element with RFID assembly but only part of the core. A separate magnetic strip storing its own unique data magnetically can be provided on the first removable element even at least partially overlying the RFID assembly for independent identification operation.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of application Ser. No. 11/099,998filed Apr. 6, 2005, now U.S. Pat. No. 7,204,652, which is acontinuation-in-part of application Ser. No. 10/279,752 filed Oct. 23,2002, now U.S. Pat. No. 6,994,262, claiming priority to Application No.60/401,789filed Aug. 7, 2002, and which is a continuation-in-part ofapplication Ser. No. 09/595,825 filed Jun. 16, 2000, now abandoned,itself a continuation-in-part of application Ser. No. 09/532,113 filedMar. 21, 2000, now U.S. Pat. No. 6,769,718, and claiming priority toApplication No. 60/139,684filed Jun. 16, 1999.

BACKGROUND OF THE INVENTION

The present invention relates to sheet products and, in particular, toprinted form sheet products with sets of uniquely encoded transactioncards, tags, labels and other removable identification elements.

Various printed sheet product including uniquely encoded identificationelements removable from a larger printed sheet product with otherelements and/or other unique information (e.g., name and address ofindividual assigned unique identifier element) are disclosed in U.S.Pat. Nos. 4,978,146; 5,863,016; 6,010,159 and 6,039,356. It would bedesirable to provide similar or other identification elements withgreater data capability and/or more diverse uses.

BRIEF SUMMARY OF THE INVENTION

In one aspect, the invention is a method of making a multilayer,integral, individual planar radio frequency identification elementcomprising the steps of: providing a first substrate sheet having majoropposing first and second sides; applying a first one of either a radiofrequency identification array antenna and a radio frequencyidentification array printed circuit chip to the first major side of thefirst planar substrate sheet; separately applying a second remaining oneof the radio frequency identification array antenna and the radiofrequency identification array printed circuit chip to the first majorside of the first planar substrate sheet in operative overlyingrelationship and connection with the first one to form an operativeradio frequency identification array on the first planar substratesheet; fixedly and permanently joining a first major outer side of asecond planar substrate sheet to the first major side of the firstplanar substrate sheet overlying the applied antenna and printed circuitchip to form at least part of a multilayer planar core having first andsecond major outer sides, at least one of the first and second planarsubstrate sheets being microvoided; fixedly and permanently applying atleast a first planar cover sheet to at least the first major outer sideof the planar core; and scoring the planar core and at least firstplanar cover sheet to define at least one multilayer, integral,individual planar radio frequency identification element removable fromthe core and at least first planar cover sheet, the planar radiofrequency identification element containing the operative radiofrequency identification array and the planar radio frequencyidentification element having opposing major planar sides fitting intoan area no greater that about three and five-eighths by about two andthree-eighths inches.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofpreferred embodiments of the invention, will be better understood whenread in conjunction with the appended drawings. For the purpose ofillustrating the invention, there is shown in the drawings embodimentswhich are presently preferred. It should be understood, however, thatthe invention is not limited to the precise arrangements andinstrumentalities shown.

In the drawings, which are at least partially diagrammatic:

FIG. 1 is a plan view of a first embodiment exemplary individual printedsheet product of the present invention with integral removable radiofrequency responsive identification element.

FIG. 2 is a cross-sectional view of the individual printed sheet productof FIG. 1 taken along the lines 2-2 in FIG. 1;

FIG. 3 is a plan view of another printed sheet product of the presentinvention incorporating the individual printed sheet product of FIGS.1-2;

FIG. 4 depicts diagrammatically a separate portable data storage elementstoring at least the unique codes of the individual printed sheetproducts of FIGS. 1-3;

FIG. 5 is a plan view of a second embodiment exemplary individualprinted sheet product with integral, removable electro/magneticidentification element;

FIG. 6 is a cross section of FIG. 5 taken along the lines 6-6 in FIG. 5;

FIG. 7 is a plan view of a third embodiment exemplary individual printedsheet product with integral, removable, electro/magnetic identificationelement;

FIG. 8 is a plan view of the opposite side of the third embodiment ofFIG. 7;

FIG. 9 is a cross section of the product of FIG. 7 taken along the lines9-9 in FIGS. 7 and 8;

FIG. 10 is a plan view of a fourth embodiment exemplary individualprinted sheet product with integral, removable, electro/magneticidentification element;

FIG. 11 is a plan view of a fifth embodiment exemplary individualprinted sheet product of the present invention;

FIG. 12 is a cross-section taken along the line 12-12 of FIG. 11.

FIG. 13 is a plan view of a sixth embodiment exemplary individualprinted sheet product of the present invention;

FIG. 14 is a plan view of a seventh embodiment exemplary individualprinted sheet product of the present invention;

FIG. 15 is a plan view of an eighth embodiment exemplary individualprinted sheet product of the present invention;

FIG. 16 is a plan view of a ninth embodiment exemplary individualprinted sheet product of the present invention;

FIG. 17 is a top plan view of a tenth embodiment exemplary individualprinted sheet product of the present invention;

FIG. 18 is a cross section view taken along line 18-18 of FIG. 17;

FIG. 19 is a bottom plan view of the embodiment of FIG. 17;

FIG. 20 is a perspective view of an initial stage of assembly of anintermediate sheet product used to make a plurality of the embodimentsof FIGS. 17-19 at the same time;

FIG. 21 is a subsequent stage of assembly using the intermediate sheetproduct of FIG. 20 to make the plurality of individual sheet productslike that of FIGS. 17-19;

FIG. 22 is a top plan view of an eleventh embodiment exemplaryindividual printed sheet product of the present invention;

FIG. 23 is a bottom plan view of the element FIG. 22;

FIG. 24 is a top plan view of a twelfth embodiment exemplary individualprinted sheet product of the present invention;

FIG. 25 is a top plan view of a thirteenth embodiment exemplaryindividual printed sheet product of the present invention;

FIG. 26 is a cross section taken along lines 26-26 in FIG. 25;

FIG. 27 is a cross section taken along lines 26-26 in FIG. 25 of analternate construction of the thirteenth embodiment; and

FIG. 28 is a perspective view of the RFID tag of the thirteenthembodiment exemplary individual sheet product of FIG. 25 mounted to aconventional identification card.

FIG. 29 depicts a plurality of exemplary antenna printed with conductiveink on a substrate forming at least part of a core;

FIG. 30 a depicts a possible layout for fabrication individual planarRFID identification elements in a larger printed sheet product;

FIG. 30 b is an exploded end view of the components of the printed sheetproduct of FIG. 30 a;

FIG. 30 c is an exploded end view depicting a variation of theconstruction shown in FIG. 30 a;

FIG. 31 a depicts another possible layout for fabrication individualplanar RFID identification elements in a larger printed sheet product;

FIG. 31 b is an exploded end view of the components of the printed sheetproduct of FIG. 31 a;

FIG. 32 depicts yet another possible layout for fabrication individualplanar RFID identification elements in a larger printed sheet product;

FIG. 33 a depicts yet another exemplary RFID assembly; and

FIG. 33 b depicts part of a core of a printed sheet product including aplurality of the RFID assemblies of FIG. 33 a.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used in the following description for convenienceonly and is not limiting. The words “right,” “left,” “lower” and “upper”designate directions in the drawings to which reference is made. Thewords “inwardly” and “outwardly” refer to directions toward and awayfrom, respectively, the geometric center of the stated component anddesignated parts thereof. The terminology includes the words abovespecifically mentioned, derivatives thereof and words of similar import.Furthermore, the term “electro/magnetic” is used to refer generally todevices that are electrical or magnetic or both and other than photonicin character, function and/or data storage or transmission.

In the drawings, like numerals indicate like elements. FIGS. 1 and 2depict a multilayer, integral, individual printed sheet product 10 a ofthe present invention which is an application form that maintains theintegrity of the identification of uniquely encoded planaridentification elements when the form is completed.

Individual printed sheet product 10 a is merely one of a number whichwould be produced at the same time as a “collection” or “set” in amanner to be subsequently described, each with a different unique code(or codes). Individual printed sheet product 10 a is depicted in FIG. 3as part of a larger, printed sheet product 10 with other individualprinted sheet products 10 b-10 d, which, with individual printed sheetproduct 10 a, form a plurality. The plurality 10 a-10 d is part of alarger collection or set of individual sheet products 10 a et seq.,which typically number in the thousands and may even number in themillions.

The individual sheet product 10 a of FIGS. 1 -3 includes a planar,flexible, printable sheet core indicated generally at 12 having planarmajor opposing first and second sides 14 and 16, the first or “front”major planar side 14 being seen in FIG. 1. Core 12 may be formed from asingle, integral, one-piece sheet of a single, uniform, printablematerial or, as is best shown in FIG. 2, core 12 may be formed byseparate first and second printable core strips 18, 20. The core strips18, 20 are each planar and flexible and, according to an importantaspect of the invention, are of different materials each of which canaccept printing. The strips 18 and 20 are fixedly secured together,generally edge-to-edge, side-by-side, to define a preferably monolayercore 12 of one thickness of material with a junction or joint 17. Onlystrip 18 forms the upper outer edge of core 12 in FIG. 1 and only strip20 forms the lower outer edge. Machine or tractor feed holes (notdepicted) can be located along the free side edge margins of each strip18 and 20, respectively, (upper and lower margins in FIG. 1) forcontinuous manufacture of complete collections or sets of the individualsheet products from rolls of the strip materials. Alternatively,collections or sets of the individual sheet products 10 can be made froma plurality of sheets like sheet product 10 of FIG. 3, each of the samepredetermined size (e.g., 8½×11, 14×17, etc.) and each of whichconstitutes a sheet product of the present invention.

Referring back to FIG. 1, the second core strip 20 is printed on thefirst major planar side 14 of the core 12 with at least one and, moretypically, a plurality of spaced-apart, variable data fields. Twovariable data fields are identified at 24 and 25. Each variable datafield 24 and 25 is printed with a unique code and the codes printed inthe variable data fields 24-25 are identical, namely, “0000000369” inthe indicated example. The variable data fields 24-25 constitute a set,each with the same unique printed code. Referring to FIG. 3, each otherindividual printed sheet product 10 b-10 d also has its own set ofvariable data fields: code fields 24 b/25 b; 24 c/25 c; and 24 d/25 d,respectively. Each set of the code fields is encoded with the same codeunique to the set and different from each other set of printed codes ofthe sheet product 10 and of the larger collection of individual sheetproducts 10 a et seq., only four of which are depicted. The location ofthe variable data fields 24-25 preferably remains the same in eachindividual sheet product 10 a, 10 b, etc. Only the unique code printedin the variable data fields would change from individual sheet product10 a to individual sheet product 10 b, 10 c, etc. The unique code may beprinted in human readable characters or in machine readable formats,e.g., bar codes, or in both formats (as depicted) in either or both ofthe first and second variable data fields 24, 25. Preferably, allprinted codes are capable of being optically as well as machine read.This construction permits all of the machine readable printed variabledata fields to be located on one of two core strips used. Of course, ifthe core 12 is formed from a single strip of core material, variabledata field 25 could be located anywhere on the sheet product 10 a,including the opposite end (upper end in FIGS. 1-3) of the sheet product10 a.

In addition to the variable data fields 24-25, the sheet product 10includes one or more printed static graphic fields with two fields 34,35, being depicted on the first side of 14 of the core 12. The secondside 16 of the core 12 typically includes at least one or more printedstatic graphic fields, two fields 36 and 37 being indicated in phantomblock diagram form on FIG. 2. Field 35 is also indicated in phantomblock diagram form in FIGS. 1 and 2. Static graphic fields generally maybe a graphic image or text or a combination, which is typically repeatedidentically on each other individual printed sheet product 10 b, 10 c,etc. of the collection or set. The static graphic field(s) 34-37typically would remain unchanged from printed individual sheet product10 a to printed individual sheet product 10 b, etc. within a set orcollection of such individual products 10 a et seq. This is particularlytrue of static graphic fields of text providing information or creatingforms. Decoration graphics need not be identical on each individualsheet product 10 a but would typically be provided in a single patternthat might span several adjoining individual sheet products and then berepeated on consecutive adjoining individual sheet products thereafter.However, they carry no unique data. One of the advantages of the presentinvention is that its construction allows the printing of information(static graphic and variable data) on both sides of the sheet productsand their various removable elements.

Static graphic fields 34, 35 are associated with the first and secondvariable data fields 24 and 25, respectively. Static graphic field 34preferably is an identification block preprinted to indicate where onthe first core strip 18, a name and address of an individual is manuallyentered to identify the individual to whom the individual sheet productand the unique code(s) of the individual sheet product 10 a et seq. areassigned. The particular formats of the various static graphic fields34-37 are not important to this embodiment of the present inventionbeyond the provision on the first planar strip 18 of a location (i.e.,static graphic field 34) to manually enter an identification of anindividual to whom the unique code(s) of the sheet product 10 a et seq.is assigned.

Referring back to FIG. 2, a first cover strip indicated generally at 40is integrally and permanently secured to the core 12 and preferably toeach of the first and second core strips 18 and 20 preferably spanningjoint 17 and holding the first and second core strips 18, 20 ingenerally edge-to-edge, side-by-side position as shown in FIGS. 1 and 2.Preferably, the first cover strip 40 only partially covers the first or“front” major planar side 14 of the core 12 but at least partiallycovers each of the first and second core strips 18 and 20 whileextending completely across the first major planar side 14 and each ofthe first and second core strips 18 and 20 (left to right in FIG. 1).The “upper” edge of strip 40 is noted in FIG. 1 by the lead line fromreference numeral 40. Preferably, the first cover strip 40 covers enoughof each of the first and second core strips 18 and 20 to assure thateach is permanently and integrally secured with the other. The firstcover strip 40 may be provided by a polymer film 42 and an appropriateadhesive layer 44, preferably a heat or light activated adhesive forpermanence.

In the depicted embodiment 10 a, a second cover strip 50 is preferablyprovided, integrally secured to each of the first and second core strips18 and 20, again only partially covering the second, “rear” major planarside 16 of the core 12 and each of the first and second core strips 18and 20. Second cover strip 50 again preferably extends completely acrossthe second major side 16 and each of the first and second core strips 18and 20, again left to right in FIG. 1 but only partially along core 12and core strip 18 in the vertical direction.

Individual sheet product 10 a further includes a planar,electro/magnetic data storage element 28, which is encoded with a uniqueelectro/magnetic code. The preferred data storage element 28 is a readonly memory, which is part of a generally planar, radio frequencyidentification (“RFID”) transponder assembly 27 configured to transmitan electro/magnetic signal containing the unique electro/magnetic codeand possibly other information in response to a radiated, e.g., radiofrequency (“RF”) interrogation signal. Such RFID assemblies include anantenna and a small chip connected to the antenna. The chip includes theread only memory as well as RF receiver and RF transmitter circuitry anda power circuit configured to temporarily store energy from the receivedRF signal and use that energy to transmit the RF response. The assembly27 may also include programmable (random access) memory and controlcircuitry. The assembly 27 is preferably permanently and integrallyfixed together with at least one of the core 12 and the first coverstrip 40, in product 10 a on the first side 14 of the core 12, by beingbonded between and with the polymer film 42 and the core 12 by theadhesive 44 of the first cover strip 40. The electro/magnetictransponder assembly 27 may be first “tacked” to the core 12 before thecore 12 is joined with the first cover strip 40 or even before the corestrips 18, 20 are joined. Such RFID assemblies 27 (also sometimesreferred to as “inlays”) are available from a variety of suppliers,including but not limited to, Motorola of San Diego, Calif.; TexasInstruments of Attleboro, Mass., Checkpoint Systems of Thorofare, N.J.;Gemplus Corp. of Redwood City, Calif.; Hughes Identification Devices ofTustin, Calif.; Cotag International of Wilmington, Del.; AbbhafoIncorporated of San Diego, Calif.; and Balough T.A G. of Ann Arbor,Mich. For example, Gemplus offered smart labels in three shapes: a smallsquare approximately one-half inch square, a large square approximatelyone inch square and a small disk. All three sizes come in two versions,read-only and read/write. Each read-only version contains a unique,tamperproof code of sixty-four bits, which is directly programmed duringmanufacture. The read/write version has a 2 kb EEPROM memory that offersdifferent access possibilities. Various additional shapes, sizes and/orcapacities are and will be available and can be used. The smallest sizeis particularly useful on key tags and other smaller elements. Typicallysuch devices require for interrogation the use of readers supplied byvarious manufacturers.

Still referring to FIG. 1, scoring indicated generally at 60 a, 60 b and60 c is provided in the sheet product 10 a and extends at leastsufficiently through and along the sheet product 10 a and through thesecond core strip 20 and, in this embodiment 10 a, through the providedfirst cover strip 40 and the second cover strip 50, where present, todefine at least one identification element 62 removable from a remainderof the individual sheet product 10 a. The scoring 60 a and 60 c furtherseparates the second printed variable data field 25 from the otherprinted variable data field(s) 24.

The first removable identification element 62 is preferably planar andmultilayer in construction and preferably includes at least the secondvariable data field 25 of the plurality of variable data fields 24-25but only a portion of second core strip 20, the first cover strip 40 andthe second cover strip 50, if provided. Preferably, one or more narrowbridges of continuous material 64-66 spanning the first removableelement 62 and the remainder of the sheet product 10 a releasably retainthe first removable element 62 in the sheet product 10 a until removed.Preferably, another portion 60 b of the scoring defines a closedperimeter opening 68 entirely within and entirely through the firstremovable element 62 to enable the element 62 to be attached to a keyring, key case or other key holder (none depicted).

Although the element 62 is generally triangular in shape, a variety ofother shapes, both non-rectangular and rectangular, could be used,although non-rectangular shapes are more distinct, and sometimes easierto use. Preferably key tag element 62 is smaller in size than aconventional credit or business card which are typically about three andthree-eighths by two and one-eighth inches or more in size, with amaximum planar diagonal dimension of about three and seven-eighthsinches in length. Key tag 62 is smaller than that having a maximumdimension in the plane of the tag 62 of less than three and one halfinches and having no second dimension in the plane of the element 62 ina direction perpendicular to the maximum dimension greater than twoinches.

Still referring to FIG. 1, according to another important aspect of thepresent invention, the scoring preferably further includes a line ofperforations 60 c (or other line of weakness), which extends across thesheet product 10 a and sufficiently through the second core strip 20,the first cover strip 40 and/or the second cover strip 50, whereprovided, to define first and second separable sheet components 72 and74. At least one of the printed variable data fields, the first variabledata field 24 in this embodiment, is separated from the removableidentification element 62 and is left on an integral remainder of theindividual sheet product 10 a which includes the first core strip 18.The first separable sheet component 72 is integral and includes theentirety of the first core strip 18 and a portion of the second corestrip 20 including the first printed variable data field 24. The secondseparable component 74 includes the removable identification element 62and a scrap portion 20 a of the second core strip 20, which is connectedto and releasably retains the removable identification element(s) 62.The second separable component 74 can be separated from the firstcomponent 72 and given to a customer or client who keeps the removableidentification element(s) 62. The first separable sheet component 72 isretained with identification information of the individual to whom thesecond separable sheet component 74 was given manually entered into thestatic graphic field 34. The first variable data field 24 with theunique printed code remains attached with the individual identificationinformation manually entered into the static graphic field 34 and iskept as a permanent record by the sheet product provider. In this way,identification element(s) with pre-entered electro/magnetic codes can beeasily assigned to randomly appearing individuals at a retail point ofdistribution and a record of that assignment easily made.

Specific manufacturing details and materials, including suggestedmaterials and manufacturing techniques, as well as other configurationsof printed sheet products including removable planar, printedidentification elements have been disclosed in prior U.S. Pat. Nos.4,978,146, 5,495,981 5,743,567, 5,769,457, 5,863,076, 6,010,159 and/or6,039,356, and application Ser. Nos. 60/126,476 filed Mar. 26, 1999,60/139,684 filed Jun. 16, 1999, 60/401,789 filed Aug. 7, 2002,09/532,113 filed Mar. 21, 2000, and 09/595,825 filed Jun. 16, 2000, eachof which is incorporated by reference herein in its entirety.Suggestedly, first core strip 18 comprises and, preferably, consistsessentially of cellulose material, namely paper stock, to reduce theoverall cost of the product 10 a. The second core strip 20 preferablycomprises a polymer material stiffer and thicker than the paper sheetstock to provide stiffness and thickness to the removable key tag (orcard) element(s) 62 yet still flexible for processing. The polymermaterial is one that accepts printing, preferably one which acceptslaser printing. Strip 20 preferably consists essentially of a porous,specifically microvoided, polymer sheet material such as Teslin® of PPGIndustries, Pittsburgh, Pa., or Artisyn® of Daramic, Inc., Charleston,S.C., both microvoided, polysilicate sheet materials for laser printing.Teslin® is described in detail in U.S. Pat. No. 4,861,644, incorporatedby reference herein. See also published U.S. Application No. 20010023014 also incorporated by reference herein. Teslin® is relativelyvery porous with a porosity of more than fifty percent.

The second cover strip 50 on the second or rear major planar side 16 ofthe planar core 12 suggestedly comprises and preferably consistsessentially of a transparent polymer film carrier 52 bonded to core 12with an appropriate adhesive 54 and is the preferred cover strip used tojoin the two core strips 18, 20 together at joint 17. This permits laserprinting of variable data fields and installation of RFID assemblies 27directly on the first side of the core 12, if desired before attachmentof the first core strip 40. Polyester provides good strength, wear andsoil resistance properties to the outer surface of each of the removableelement(s) 62 etc. However, if durability of the removable element(s) isnot a factor and reduced cost would be advantageous, the polymer filmcarrier 52 of the second cover strip 50 can be a less expensive materialsuch as conventional cellophane or 3M brand Magic invisible ortransparent tape or any of their industry equivalents with a pressuresensitive adhesive sufficient to hold the core strips together, at leastuntil the first cover strip 40 is applied spanning the joint 17. Atleast the first cover strip 40 on the first (front) major planar side 14of the core 12 and individual sheet product 10 a would suggestedly be amore durable, polyester material that is transparent to visible light orat least infrared light so that the variable data fields 24, 25, etc.beneath the cover strip 40 can be seen by humans, if desired, or atleast read by machine such as by an infrared scanner.

While both strips 40, 50 are shown to extend over the junction 17between the first and second core strips 18 and 20, only one of the twocover strips 40 or 50, if it is actually used as the sole means to jointhe first and second core strips 18, 20 together, need span the junction17 for purposes of the present invention. Similarly, cover strip 50 neednot be provided at all. The primary purpose for providing second coverstrip 50 is to protect the rear face of the removable element 62 and tofurther prevent tampering with the printed fields on that side of theelement. For that purpose, second cover strip 50 need only span thesecond core strip 20 overlapping the scoring 60 a defining the removablecard element 62. The upper edge of one of the cover strips 40, 50 might,for example, terminate at a location between the scoring 60 a and thefirst printed variable data field 24, or at a location just abovevariable data field 24 spanning the scoring 60 a-60 c and first variabledata field 24, if that field is to be protected as well. If desired, theupper edges of both cover strips 40, 50 can be terminated betweenscoring 60 a and data field 24 and another adhesive strip, e.g.,transparent tape, used to join the core strips.

FIG. 3 depicts yet another printed sheet product 10 of the presentinvention, which is formed by a plurality of individual sheet products10 a, 10 b, 10 c and 10 d, respectively. The sheet product 10 is printedwith a plurality of sets of variable fields, four being shown: 24/25; 24b/25 b; 24 c/25 c; and 24 d/25 d. The printed codes of each set 24/25,24 b/25 b, 24 c/25 c and 24 d/25 d, are identical in the set, unique tothe set and to the individual printed sheet product 10 a, 10 b, 10 c, 10d and differ from each other unique set of printed codes of each otherindividual printed sheet product 10 a et seq. of the set. The same istrue for the data storage elements 28, 28 b, 28 c and 28 d. Each suchdata storage element 28, et. seq., is encoded with its own uniqueelectro/magnetic code, which differs from the electro/magnetic code ofeach other element 28, 28 b-28 d and that of each other data storageelement in the total set or collection of individual sheet products ofwhich products 10 a-10 d are part. The printed sheet product 110 furtherindicates the locations of additional score lines 160 a-160 d whichdefine and separate individual printed sheet products 10 a-10 d from oneanother and from any remainder of the overall sheet product 110, such assections 161 a-161 d, which are scrap. Also the core strip 18 may bemade bigger to provide extended areas 18 a-18 d on each removableelement 10 a-10 d, preferably with another static graphic field 38 a-38d, respectively, which might be a logo or instructions or a coupon, etc.and may be made removable by score line 160 e (in phantom). Equipment towrite codes on and/or read codes from magnetic strip 128 can be obtainedfrom any of a variety of domestic and foreign manufacturers, including,but not limited to, Axiohm American Magnetics of Cypress, Calif.,Mag-Tek, Inc. of Carson, Calif. and Atlantic Zeiser of West Caldwell,N.J.

Where the unique electro/magnetic code of each individual sheet product10 a et seq. is different from the unique printed code, a master dataset must be provided linking the two codes (electromagnetic/printed)with one another and, if known, with any individual to whom theindividual sheet product 10 a-10 d and thus the unique printed andelectro/magnetic codes of that individual sheet product are assigned.This may occur because some transponder manufacturers will only shipelectro/magnetic data storage assemblies precoded according to their owncode schedules. This is expected to change. Alternatively, theassemblies can be obtained with programmable memories allowing otherdata, including other codes, to be written into data storage. FIG. 4depicts diagrammatically a separate, preferably portable data storageelement 100 storing at least the unique printed code and the uniqueelectro/magnetic code of each individual sheet product 10 a et seq. in asingle data set. This information may be further combined with anidentification of an individual person assigned the individual printedsheet product 10 a et seq. and the two codes (printed andelectro/magnetic) organized in a manner such that at least the two codes(printed and electro/magnetic) of each individual sheet product 10 a etseq. and, where available, the identification of the individual personassigned the codes and the individual sheet product, can be identifiedfrom among pluralities of unique codes (printed and electro/magnetic)and preferably a plurality of individual person's identifications on theportable data storage element 100. The printed codes of sheet products10 a-10 c are indicated diagrammatically at 10 a′-10 c′. The portabledata storage element 100 might be any element with adequate data storageincluding an optical disk, a floppy disk, a hard drive, a magnetic tape,a programmable memory (e.g., ROM, RAM), etc. Alternatively, theinformation may be stored in a memory and accessible by phone, Internetlink, satellite link, etc., to correlate the codes to an individual'sidentity or vice versa. This can be done as a separate step or whileaccessing a central data base of customers to add additional informationto that maintained on the individual, for example, product purchases,visits, etc. The printed codes and electro/magnetic codes of eachindividual sheet product may be related to one another by an algorithm,including a one-to-one algorithm for identical printed andelectro/magnetic codes on each individual sheet product. Alternatively,the codes can be random and would have to be related to one another insets in the other data storage element 100.

A collection of the individual sheet products 10 a et seq. might bemanufactured from pluralities of cut, printed sheet products like sheetproduct 10 of FIG. 3 or may be made continuously from rolls of flexiblecomponent stock. Parallel alignment of the core strips 18, 20 and firstand second cover strips 40 and 50 permits such a continuous manufacture.The RFID transponder assemblies 27 may be supplied on a suitablecontinuous carrier, for example a thin polymer or cellulose strip (notdepicted), with the assemblies fastened to the strip at uniform spacingpreferably to coincide with the appropriate position of such assembly onthe individual printed sheet product 10 a, etc. on a cut sheet likeproduct 10 of FIG. 3 or on a continuous web. See, in particular,previously referenced U.S. Pat. Nos. 5,769,457, 5,863,076, 6,010,159 and6,039,356 for details of the cut sheet and continuous strip manufactureof individual printed sheet products 10 a et seq.

FIG. 5 is a plan view of FIG. 1 of an alternate individual printed sheetproduct 110 a including a different type of planar electro/magnetic datastorage element 128. Apart from the changes associated with this datastorage element 128 and the different variable printed code fields124/125, the individual printed sheet products 10 a, 110 a areessentially identical in composition, form and use. The differencesbetween the products 10 a and 110 a are best seen in FIG. 6, across-sectional view of the lower portion of FIG. 5. Everything abovethe joint 17 in both products 10 a, 110 a is identical.

Referring to FIG. 6, integrally and permanently applied over the outerside of first cover strip 40 is the planar data storage element 128 inthe form of a conventional magnetic strip, which is fixed permanentlyand irremovably to the outer surface of first cover strip 40 by suitablemeans such as an adhesive layer 127. Magnetic strip 128 can beelectro/magnetically encoded with and can store a uniqueelectro/magnetic code, as well as further information if a sufficientamount of the magnetic strip 128 can be provided on the removableelement 162. Unlike the limitations of the RF transducer data storageelement 28, the magnetic strip 128 can easily be magnetically encodedduring manufacture of the sheet products 10 a, etc. with the same uniquecode printed in each of the variable data fields 124, 125 of theindividual sheet product. In addition to this construction, it should beappreciated that the magnetic strip 128 can be embedded in an otherwisethin transparent cover strip and applied to the core as a single,composite cover strip (neither depicted). Pluralities of such individualsheet products can be fabricated together in the manner described withrespect to FIG. 3 by substituting a continuous magnetic strip 128 (inphantom in FIG. 3) spanning the individual sheet products. Where aremovable identification element includes either a printed uniquemachine readable code (e.g. 24) or magnetic stripe (e.g. 128) proximalan edge of a removable identification element (e.g. 162), the closedperimeter opening (e.g. 68) should be located at least one-half inch ormore from an edge of the element along which the magnetic stripe (128)extends and at least one inch from any edge that the printed machinereadable code (25, 125, etc.) adjoins or that a magnetic strip adjoinsbetween the printed machine readable code and the edge. This is so thatthe opening (68) does not interfere with the operation of a mag stripeor bar code swipe reader through which the element is passed. Accordingto another important aspect of the invention, an RFID transponderassembly like assembly 27 in FIGS. 1-3 can be provided in removableelement 162 permanently and integrally fixed to the element, preferablybetween core strip 20 of core 12 and one of the cover strips 40, 50.

FIGS. 7 and 8 are plan views and FIG. 9 is a cross-sectional view,respectively, of yet a third embodiment, multilayer, integral,individual printed sheet product of the present invention indicatedgenerally at 210 a. It should be appreciated that individual printedsheet product 210 a is substantially similar to that portion ofindividual printed product 10 a of FIGS. 1-4 below the junction 17 towhich an additional element, an exposable, adhesive layer 280, has beenadded. Referring particularly to FIG. 9, layer 280 is preferably apressure-sensitive adhesive, and is further provided with a protectiverelease strip 282 overlying the layer 280 until it is desired to exposethe adhesive layer 280 for use. Scored key tag 262 constitutes the firstidentification element removable from the individual sheet product. Theportion of the individual sheet product 210 a above the score line 60 c,including the first variable data field 24 with unique printed code andthe exposable adhesive layer 280, constitutes a second planaridentification element 270 removable from the remainder 261 of theindividual printed sheet product 210 a. The second removableidentification element 270 can be used as a label, for example, attachedto a separate enrollment card or enrollment sheet containing anidentification of the individual person to whom the remainder of theindividual printed sheet product 210 a with first removable element 262is provided. If desired, a line of scoring 60 d can be provided acrosseither side of removable element 262 to remove end 261 a of the sheetproduct during manufacture.

FIG. 10 is a plan view of a fourth embodiment, individual printed sheetproduct indicated generally at 310 a, which is substantially identicalto individual printed sheet product 10 a of FIGS. 1-3 but for thesubstitution of a new static graphic field 39 and a new variable datafield 26 containing preprinted information of the unique individualperson to whom the printed sheet product 310 a and the unique printedcode of the other printed variable data fields 24/25 and the uniqueelectro/magnetic code of the planar electro/magnetic data storageelement 28 are assigned. Element 310 a is preferably sized to beslightly smaller than and essentially fully fill a standard sizeenvelope (e.g., No. 9) without bending or significant movement of thesheet product 310 a within the envelope so that the name and address offield 26 can be viewed through a window of the envelope (not depicted).A new first separate sheet component 372 is thus provided. It will beappreciated that variable data field 24 could be deleted in view offield 26 and another identification element (key tag or card) providedbetween the existing key tag 62 and printed fields 26 and 39. Also, amagnetic storage element/strip 128 like that in FIGS. 5 -6 can be addedto or over either cover strip 40, 50 of the third embodiment printedsheet product 210 of FIGS. 7-9 or an RFID transponder assembly 27 addedto the fourth embodiment 410 a of FIGS. 11-12 to provide the twoseparate electro/magnetic data storage devices on the removable element262 or 126.

It will be apparent that various modifications could be made to theindividual sheet product 210 a. For example, either or both of the firstand second cover strips 40 and 50 can be terminated short of the firstvariable data field 24 and line of perforations 60 c as they are notneeded to secure two core strips together. This is exemplified inanother possible sheet product embodiment 410 a, which is depicted inplan view in FIG. 11 and cross-sectional view in FIG. 12. Sheet product410 a further differs from sheet product 210 a in the substitution ofmagnetic strip 128 for transponder assembly 27 as done with the secondembodiment 210 a. Given the fact that a unique code is encoded eitherinto the memory 28 of the transponder assembly 27 or on the magneticstrip 128, it will be appreciated that, if desired, printed variabledata field 25, 125 can be omitted from the removable element 62, 162,262. On the other hand, the line of perforation 60 c of FIGS. 1-2 and7-9 can be converted into a complete cut 60 e as in FIGS. 11 and 12 anda larger adhesive layer 480 and protective release strip 482 can beapplied to span the complete cut 60 e to releasably hold the secondremovable identification element 470 with the remainder of the printedsheet product 410 a, which is provided by second separable component 474that includes key tag 162 and remainder 461. Alternatively or inaddition, adhesive layer 480 and protective strip 482 can be appliedfurther along the sheet element 410 a as shown in phantom in FIG. 12 at480′ and 482′ to span at least a proximal (upper) portion of the firstremovable element 162 to releasably secure each such element in thesheet product 410 a. Again, an RFID transponder assembly 27 can be addedto the removable element permanently and integrally fixed together withthe core 12 and one of the cover strips 40, 50.

A larger, rectangular transaction card 562 can be substituted for thekey tag 262 or a combination of planar, rigid, identification elements(card(s) and/or tag(s)) provided with the labels 570 as shown in FIGS.13 and 14, which depict exemplary individual sheet product embodiments510 a and 610 a, respectively.

Embodiment 510 a of FIG. 13 includes a removable card element 562, aremovable label element 570 separated from one another and a remainderof the individual sheet product 510 a by scoring 560 a and 560 b,respectively. Variable data fields 524 and 525 are printed on a core512, which is exposed on and around label element 570. The removablecard element also bears magnetic strip 528 and printed static graphicfield 534. One or more other static graphic fields are typicallyprovided on the hidden major side of sheet product 510 a. Theoverlapping lower boundaries of first and second cover strips 540/550 onthe depicted and opposing major sides, respectively, are indicated insolid while the overlapping upper boundaries of the exposable adhesivelayer 580 and overlying protective release strip 582 on the hidden majorside of the sheet product 510 a are indicated in phantom. Cover strips540, 550 extend across product 510 a completely covering both majorsides of card 562. If desired, an additional line of scoring 560 c canbe provided to permit the sheet product 510 a to be broken into firstand second separable components 572 and 574 indicated (in phantom).

Embodiment 610 a in FIG. 14 includes a removable card element 562 and aremovable label 570 identical to that of FIG. 13 and further includes athird removable element, a key tag 690, with a third printed variabledata field 526 bearing the same unique code as code fields 524 and 525.Key tag 690 is defined by scoring 660 a, 660 b. If desired, a second keytag could be formed nested with key tag 690 to provide three card andkey tag identification elements. Again, individual sheet products 510 aand 610 a are designed so that each magnetic strip(s) and exposableadhesive layer(s) and protective release strip(s) can be laid with coverstrips on a printed core to produce many side-by-side, individual sheetproducts at one time, either on cut sheets or continuous rolls of corematerial.

FIGS. 15 and 16 show other, related individual sheet product embodiments710 a and 810 a. Sheet product 710 a in FIG. 15 includes a removablecard element 762, a removable label 770 and a removable key tag element790 in another possible configuration. Each removable element bears aseparate printed variable data field 724, 725 and 726, respectively,preferably in both character and bar formats. As is indicated, a firstmagnetic strip 728 is applied to span removable key tag element 790. Asecond magnetic strip 778 may be applied in addition or in thealternative and spans the removable card element 762. Finally, exposableadhesive layer 780 with protective release strip 782 are applied to theopposite major side of the sheet product 710 a underlying the removablelabel 770. Cover strips 740, 750 can span the entire sheet product asindicated or portions of the product 710 a including card element 762and key tag elements 790. Individual sheet product like 710 a could bemade in continuous strips, side -by-side and separated by scoring aftercompletion utilizing continuous lengths 728, 778 of the magnetic stripmaterial and exposable adhesive layer 780 and protective release strip782 material. Scoring 760 a, 760 b defines key tag 790; scoring 760 cdefines removable label 770 while scoring 760 d defines removable card762. Additional scoring 760 e, 760 e′ and 760 f, 760 f′ can be providedto define removable scrap portions or elements 761, 761′. Sheet product810 a in FIG. 16 is identical to sheet product 710 a of FIG. 15 but forthe addition of a second removable key tag element 790′ defined byscoring 760 a′, 760 b′ and bearing printed variable data field 726′ anda portion of magnetic strip 728. Again, it will be appreciated that thevarious removable identification elements 562, 762, 790, 790′ can beprovided with an RFID transponder assembly 27 a, etc. in place of or inaddition to the indicated magnetic strip data storage element 528, 728,778.

In addition, it will be appreciated that still other, differentcombinations of removable elements including combinations with multiplekey tags, cards, labels, advertisements, application forms, etc. andother printed variable and static-graphic data fields can be provided indifferent configurations of the individual sheet products.

The uniquely, electro/magnetic encoded, identification elements of theabove-described embodiments of the present invention offer certainadvantages over such elements which are uniquely encoded with onlyconventional, optically read, printed bar coding. First, they canprovide greater data storage in a given area. Second, they offer thecapability to rewrite some of the data being stored, so that the cardcan be used transactionally. Third, because they contain their ownunique machine readable code, they do not actually require printed codes(e.g., 25, 125, 525, 725, 726, 726′). Such codes can, however, be usefulat point of sale locations and to easily identify one unique codeassigned to the individual receiving the individual sheet product.Finally, identification elements with the RF transducer assembly can beread remotely, that is without having to be physically swiped through areader. Some systems are sufficiently powerful to be able to interrogateand respond, even without being removed from a pocket or purse, andprovide even greater flexibility for customer or client identificationand for financial transactions (e.g. credit and debit cards).

FIGS. 17-19 are plan, cross sectional and opposite plan views,respectively, of a tenth embodiment, multi-layer, integral, individualprinted sheet product of the present invention indicated generally at1010 a. Sheet product 1010 a is merely one of a number that would beproduced at the same time as a collection or set as depicted inconnection with FIGS. 20-21. Referring to the FIG. 18 cross section, theindividual sheet product 1010 a includes a planar, flexible, printablesheet core indicated generally at 1012 having major planar opposingfirst and second sides 1014 and 1016, a first major planar side 1014being seen in FIG. 17 and the opposing, second major side 1016 beingseen in FIG. 19. Core 1012 is preferably provided by separate first andsecond printable core strips 1018, 1020 which are planar, flexible andaccept printing, and preferably are the microvoided, polysilicate sheetmaterials previously mentioned. The core strips 1018, 1020 areoverlapping and coextensive in the product 1010 a. Core strips 1018,1020 can be joined together with and by any means suitable for thematerials selected and as intended. Preferably the microvoidedpolysilicate materials are permanently bonded together with a layer 1019of suitable adhesive material such as WC9-PL, a heat activated, waterbased polyurethane adhesive of the Thomley Company of Wilmington, Del.Sandwiched between the core strips 1018, 1020 is a radio frequencytransponder assembly 27, which is preferably permanently and integrallyfixed together with each of the core strips between the core strips1018, 1020. Again, assembly 27 includes electro/magnetic memory portion28 (in phantom in FIG. 17) containing the unique electro/magnetictransponder code. Preferably, first and second cover strips 1040, 1050are again integrally and permanently secured to the outer facing sides1014, 1016, respectively of the first and second core strips 1018, 1020,respectively. Each cover strip 1040, 1050 preferably is transparent andextends at least transversely entirely across the individual sheetproduct 1010 a on the first and second major planar sides 1014, 1016,respectively, of strips 1018, 1020 of the core 1012. At least one and,more typically, a plurality of spaced-apart, variable data fields, e.g.,1024 and 1025, are printed on the core 1012 with a unique sixteen digitprinted code which is identical to one another, namely “4215 6532 87459321” in this example. The variable data fields 1024, 1025 constitutes aset, each with the same unique printed code. Referring to FIG. 20, eachother individual printed data sheet product 1010 b-1010 j of thecollection or set of such individual products has its own set ofvariable data fields 1024 b/1025 b, 1024 c/1025 c, etc., each coded withthe same code unique to that set and different from that of each otherset of printed codes of the larger sheet product 1010 and largercollection of individual sheet products 1010 a, etc., only ten of whichare depicted. Again, each element may include a printed variable datafield with other data unique to the set such as name and address orsocial security account number of the recipient. The location of thevariable data fields 1024, 1025 with printed codes preferably remainsthe same in each individual sheet product 1010 a, 1010 b, etc., of theset. Only the unique code printed in the variable data fields withprinted codes would change from individual sheet product 1010 a toindividual sheet product 1010 b, etc. Again, the unique code is printedin human readable characters or numbers, or in machine readable format(e.g. bar codes) or in both formats (as depicted) in some of all of thevariable data fields 1024, 1025. In addition to the variable data fields1024, 1025, etc., the printed sheet product 1010 a includes one or morestatic graphic fields with an individual field 1034 being identified onside 1014 and with all or substantially all of the exposed side 1016being covered by a single large static field covering or essentiallycovering the second major planar side 1016, which typically would be thedecorated “front” side, or a plurality of individual static graphicfields as indicated in phantom at 1036, 1037. It should be appreciatedthat this does not preclude a static graphic field from differing inappearance from element to element as where a large overall staticdesign is applied to blocks of the individual elements (e.g., 1010a-1010 j) so no static graphic field is the same from element toelement. However, such difference static graphics fields carry noinformation unique to the card, which could be used to uniquely identifythe holder of the card. In the same way, not all printed information isvariable data. The name of the entity issuing the sheet products 1010 a,etc., which appears on all of the products, is not variable data whichcan be used to uniquely identify the individual issued on individualsheet product 1010 a or 1010 b etc.

Scoring, indicated generally at 1060 a, 1060 b and 1060 c, is providedin the sheet product 1010 a and extends at least sufficiently throughand along the sheet product 1010 a and through the core 1012 and throughthe first cover strip 1040 and second cover strip 1050, where present,to define at least one identification element 1062 removable from aremainder of the individual sheet product 1010 a. Scoring 1060 a and1060 c further separates the second printed variable data field 1025from the other printed variable data field(s) 1024.

The first removable identification element 1062 is, again, preferablyplanar and multi-layer in form and preferably includes at least thesecond printed variable data field 1025 of the plurality but only aportion of the core 1012 and core strips 1018, 1020, the first coverstrip 1040 and second cover strip 1050, if provided. As depicted, coverstrips 1040, 1050 extend entirely across the sheet product 1010 a in atransverse direction but not in the longitudinal direction. At least thefirst cover strip 1040 could be extended as indicated in phantom at1040′ to cover the remaining printed variable data field 1024 to providelong term protection to that data field. The second cover strip couldalso be extended but such extension is also unneeded in this sheetproduct. Preferred again, one or more narrow bridges of continuousmaterial 1064-1066 spanning the first removable element 1062 and aremainder of sheet product 1010 a releasably retain the first removableelement 1062 in the sheet product 1010 a until removed. Preferably,another portion 1060 b of the scoring defines a closed perimeter opening1068 entirely within and through the first removable element 1062 toenable that element 1062 to be attached to a key ring, key case or otherkey holder (none depicted). Again, element 1062 is smaller in size thana conventional credit or business card each of which is typically aboutthree and three-eighths inches by two and one-eighth inches in size. Keytag 1062 preferably but not necessarily has a length of about two andone half inches and a height of about one and five-eights inchesproviding a maximal diagonal dimension between opposing corners of aboutthree inches or less (2.98″). Again, the element 1062 has no dimensionin the plane of the elements in a direction perpendicular to the maximumdiagonal dimension greater than two inches. These dimensions makeelement 1062 an essentially reduced size version of a standard sizedcredit/debit (CR80) card.

The remaining line of scoring 1060 c is preferably a line ofperforations, but could be another form of a line of weakness, whichextends across the individual sheet product 1010 a and sufficientlythrough the core strip 1012, first cover strip 1040 and/or second coverstrip 1050, where provided, to define first and second separable sheetcomponents 1072, 1074, one of which 1072 is a second removableidentification element in the form of an adhesive label bearing at leastthe printed first data field 1024. The remainder of portion 1074excluding element 1062 is scrap.

In addition to the radio frequency transponder assembly 27, whichincludes an electro/magnetic data storage element 28 a, removableidentification element 1062 is preferably provided with a magnetic stripdata storage element 128 encoded with its own unique electro/magneticcode, which differs from the electromagnetic code of the magnetic stripdata storage element of each other individual sheet product 1010 b, etc.of the set. The unique code is preferably the same as the unique printedcode, i.e. the code of variable data fields 1024, 1025, but may be thesame as part or all of the code of the transponder assembly 27 or haveboth codes or have coding entirely different from each printed variabledata field code and each of transponder code of the set of individualelements 1010 a, etc.

FIGS. 20 and 21 depict a suggested method of construction of pluralityof the individual sheet elements 1010 a, etc., in particular 1010 a-1010j. A single sheet 1011 of the preferred, microvoided, polysilicatematerial twice the needed width, is made foldable by a line ofperforations 1013 along its center so as to divide the sheet 1011 intotwo leaves 1084, 1086. The outer side of the sheet 1011, hidden in FIG.19, is preferably preprinted with both static graphic and variable datafields before assembly. Printing on the two leaves 1084, 1086 can bedifferent or identical or may be provided on only one leaf. Preferably,a suitable adhesive such as WC9-PL, identified above, is applied as alayer 1088 on the inner side sheet 1011 exposed in FIG. 20. Thisadhesive is tacky when dried after application but before heatactivation, so that a separate sheet 1090 containing ten RFIDtransponder assemblies 27 a-27 j on a carrier 1092 such as a thin sheetof polyester, can positioned over the exposed inner side of the firstleaf 1084 such that each transponder 27 a-27 j will lie within theinterior of each of ten individual sheet products 1010 a-1010 j,respectively, the outlines of which are indicated in broken lines inFIG. 20. It may be desirable to individually place assemblies 27 a-jetc. between the leafs 1084, 1086, trimmed so as to lie well within themargins of each first removable element 1062 so that the sheets 1084,1086 can bond directly together entirely around the assemblies for eachelement. This might be done automatically by scoring or perforatingaround each transponder 27 a-27 j and punching the transponders from thecarrier 1092 onto leaf 1084 (or 1086) with tacky exposed adhesive. Theoutlines of variable data fields 1024, 1024 b, etc. and 1025, 1025 b,etc. as well as the first removable identification element 1062 and thesecond removable identification element 1072 are indicated for element1010 a and others of the elements 1010 b-j. After the transponders 27a-27 j of sheet 1090 are applied to leaf 1084, the remaining, secondleaf 1086 is folded over onto the inner side of leaf 1084 with thetransferred transponders 27 a-27 j. The remainder of carrier 1090 can bediscarded. Thereafter, as shown in FIG. 21, a first continuoustransparent cover sheet 1042, portions of which become the first coverstrip 1040 of each individual sheet product 1010 a, etc. and a pair ofseparate, continuous magnetic stripes 44′ integral with a continuoustransparent cover sheet 1042 is applied to the outer side of interimsheet product 1011′ produced by the steps illustrated in FIG. 20. Theouter side of leaf 1084, which outer side constitute major planar side14 of each of the individual sheet products 1010 a-j, is depicted. Asecond continuous cover sheet 1052 may be applied to the other outersurface of interim sheet product 1011′ (i.e. the outer side of leaf1086), which becomes the major planar side 1016 of each individualproduct 1010 a-j. Preferably temperature activated, water basedadhesives for the particular sheet materials selected are used to applythe various cover sheets 1042, 1052 (and magnetic data stripe(s), ifseparately applied provided). “MR”, a heat activated adhesive fromTransilwrap Co. of Strongsville, Ohio, can be used. The entire assembly(1011′, 1042, 1052) is passed through an activator 1054, if necessary(in phantom), and rollers (one indicated at 1056) to completelamination. Continuous carrier strips 1089, carrying the pressuresensitive adhesive forming layer 1080, are applied to the underside oflaminated intermediate sheet product 1011″. The laminated sheet product1011″ with strips 1089 is passed through a scorer 1058, which separateseach individual sheet product 1010 a-j from one another and from theremainder of the sheet 1011″, which is scrap, and further defines theindividual removable elements 1062, 1072, scrap 1074 and closedperimeter opening 1068 of each individual sheet product 1010 a, etc. Ifthe unique code stored magnetically on the magnetic data strip 1028differs from either the printed code 1024/1025 or the RF transpondercode in storage 28, it would be desirably and may be necessary toprovide yet another data set on a portable data storage element likeelement 100 of FIG. 4 with respect to the collection of the individualsheet products 1010 a et al. It has been found possible to encodemagnetic strips 128 continuously applied to a continuous sheet productlike 1011′, 1011″ before the individual removable elements are scored orremoved from the continuous sheet. Equipment is currently available fromAtlantic Zeiser of West Caldwell, N.J., which permits the combination ofoptical reading of printed bar codes (e.g. 1024, 1025 et al.) on thecontinuous strip product

and encoding the appropriate magnetic code on the magnetic stripmaterial 44′ before the continuous sheet product 1011″passes through thescorer 1058.

FIGS. 22 and 23 show opposite major planar sides of an eleventhembodiment, multi-layer, integral, individual printed sheet product ofthe present invention indicated generally at 1110 a. Sheet product 1110a is virtually identical to sheet product 1010 a but for a differentshape and size to the first removable identification element 1162, whichis generally bullet shaped rather than rectangular like element 1062 andsmaller than element 1062. Various individual features of sheet product1110 a have been numbered and correspond to those of sheet product 1010a incremented by 100. The cross section of the embodiment 1110 a wouldbe generally the same as that shown in FIG. 18 with identical componentsbut possibly different lengths for elements 1062, 1162. Sets orcollections of multiple individual sheet products 1110 a, etc. would bemade in the same manner of products 1010 a, etc. as shown in FIGS. 20and 21. It should be noted that the individual products 1110 a, etc. canbe appropriately sized and laid out on sheet of the core material suchthat same carrier 1090 with multiple RFID transponder assemblies 27 a,etc. can be used in the manufacture of elements 1110 a, etc. as well asother elements 1010 a, etc. Other shapes, in particular the generallytriangular shape magnetic tags of FIGS. 7-12 can be made in the samefashion.

FIG. 24 depicts a plan view of a twelfth embodiment exemplary individualprinted sheet product of the present invention indicated at 1210 a. Thisproduct is substantially identical to the previous products but for theshape of the base of the first removable identification element 1262which is generally rectangular beneath a generally triangular upperportion of the element such that the lateral opposing edges 1228 a, 1228b of the magnetic stripe 1228 are substantially parallel to one another.

Scored sections 1274 and 1275 are both scrap and can be removedseparately from section 1272. The RFID transponder assembly 1227 a isfrom a different manufacture and a different shape from those shown inthe devices of FIGS. 17-24. However, assembly 1227 a has its ownelectro/magnetic storage element indicated diagrammatically at 1228 a inphantom containing a stored unique electro/magnetic code. However,pluralities of the transponders 1227, each with its own, unique, storedelectro/magnetic code, would be supplied in sheets similar to sheet 1090in FIG. 20 for the production of several individual sheet products 1210a, etc. at one time. Again, a magnetic stripe 1228 is provided forelectro/magnetic data storage of various data including a separateunique electro/magnetic code which may or not be the same as the codestored in the assembly 1227 a or printed on the core at 1224, 1225, butdifferent from each other code stored on any magnetic stripe element ofany other individual sheet product (e.g. 1210 b, etc.). Finally, printedunique codes 1224, 1225 are provided on each individual element 1210 a,etc. The printed unique code “1154” is shown only in a numeral formatbut the bar code representation could be provided as well in variabledata field 1225, if desired.

FIGS. 25 and 26 are plan and cross sectional views, respectively, of athirteenth individual printed sheet product of the present inventionindicated and generally at 1310 a. As with embodiment 1010 a of FIGS.17-19, individual printed product 1310 a has a core indicated generallyat 1312, which is preferably provided in the embodiment of FIG. 26 byseparate first and second flexible core strips 1318, 1320 of printablematerial, preferably a microvoided, polysilicate material like thatdescribed previously. The two core strips 1318, 1320 are preferablyjoined together and around an RFID transponder assembly 1327 a. Outersurfaces of the core strips 1318 and 1320 define major planar opposingfirst and second sides 1314, 1316, respectively of the core. Majorplanar side 1314 is shown in plan view in FIG. 25. At least the onemajor side 1314 is printed with a plurality of variable data fields1324, 1325, 1326, each bearing the same unique printed code, in thisexample, 0000098. The code in each variable data field is printed inboth numeral and bar formats. If desired, a first flexible preferablytransparent cover strip 1340 (indicated in phantom in FIG. 26) can beintegrally and permanently secured to the first side 1314 of the core1312 by appropriate means such as an appropriate adhesive layer 1341(also in phantom). The electro/magnetic data storage element 1328 a ofthe assembly 1327 a is further indicated in phantom in FIG. 25. Finally,an exposable pressure sensitive adhesive layer 1380 is applied to themajor planar side 1316 of the core 1312 and is covered with a removable,protective release strip 1382 which backs the entire individual sheetproduct 1310 a. The individual sheet product 1310 a further includesscoring 1360 a, 1360 b, etc. through the core 1312 and the first coverstrip 1340, if provided, to define a plurality of individualidentification elements separable from one another and removable fromthe overall product 1310 a. Preferably, scoring 13 60 a defines a firstremovable element 1362 including both the RFID transponder assembly 1327a and the first variable data field 1324 with unique printed code aswell as the static graphic field 1336. Scoring 1360 b defines a secondremovable identification element 1373 bearing a second variable datafield 1325 with the unique printed code. Finally, scoring 1360 c definesyet a third removable identification element 1372 bearing the thirdvariable data field 1326 with the unique printed code. Preferably, thescoring 1360 does not extend entirely through the individual printedsheet product 1310 a but stops after passage through the core 1312 or atleast before cutting entirely through the removable protective strip1382. Done in this fashion, each scoring 1360 a, 1360 b, 1360 c can be acontinuous loop. The elements 1362, 1372, 1373 are removable from theindividual sheet product by peeling back a remaining portion 1374 of theindividual sheet product from around each of the removable elements1362, 1372, 1373, which then can be applied to the surface of anydesired object.

FIG. 27 depicts an alternate possible construction of printed sheetproduct 1310 a referred to as 1310 a′ in FIG. 27. FIG. 27 is also a viewtaken along the lines 26-26 in FIG. 25. In this form, individual sheetproduct 1310 a′ includes a flexible sheet core 1312′ preferably formedby only a single sheet of the microvoided, polysilicate printablematerial previously identified. The core sheet 1312′ has two opposingmajor planar sides, first side 1314 seen in FIG. 25 and a second side1316′. Permanently and integrally fixed together with the second side1316′ of the core 1312′ is the RFID transponder assembly 1327 a with itsRF responsive data storage element 1328 a. Finally, an exposablepressure sensitive adhesive (PSA) layer 1380 preferably is applieddirectly to side 1316′ of the core 1312′ and over the exposed surface ofthe transponder assembly 1327 a. A removable protective release strip1382 is applied over the PSA layer 1380. Thus, individual sheet product1310 a′ is substantially identical to the construction 1310 a of FIG. 26but lacks a second core strip 1320. Scoring 1360 a′, 1360 b′, 1360 c′,extends only through the single layer 1318 forming core 1312 and anyfirst cover strip 1340, if provided, to define the three removableelements 1362′, 1372′, 1373′.

FIG. 28 depicts the use of the removable elements of the individualsheet product 1310 a of FIGS. 25-27. RFID tag 1362 is applied to oneside of a conventional identification card 1300 thereby providing amachine readable, permanently stored electro/magnetic unique code to thecard 1300. The other removable identification elements 1372, 1373 (andadditional identical or similar elements, if desired) can be used tomark other documents used to record or to notify others of the identityof the individual who was assigned the unique electro/magnetic code.

As an example, RFID individual printed sheet products with removableRFID tag element with electro/magnetic unique code and magnetic stripepreviously described have been made using Teslin® microvoided,polysilicate sheet, Texas Instrument Tag-it™ HF-I miniature, rectangulartransponder inlays and high coercivity magnetic stripe material of JCPEnterprises Inc. of Gardnerville, Nev. The PSA coated cover stripmaterial may be obtained from Enterprises Tape Co. of Dalton, Ill. amongothers. The transponders have 64 bit, factory installed unique codes andapproximately 2000 bits of rewritable data storage. The magnetic stripematerial successfully used with these transponders had a nominal writecoercivity of 2750 Orsteads. There was no perceived interaction orinterference between the magnetic stripe material (even the highcoercivity material) and the transponder assembly. Each was able to besuccessfully read by conventional magnetic swipe and transponderinterrogation units, even with the magnetic stripe at least partiallyoverlying the RFID assembly.

The magnetic strip data storage element 128 can be of a conventionallylow coercivity for writing purposes, such as about three hundred Oerstedas is found on most conventional debit and credit cards, or a high writecoercivity of more than one thousand Oersted, preferably more than twothousand and more preferably between about twenty-seven hundred and fourthousand Oersted. Low or high coercivity magnetic strip may be obtainedfrom various manufacturers including Green Corp Magnetics, Inc. having abusiness location in Havertown, Pa. or JCP Enterprises, Inc. having abusiness address of Gardenerville, Nev. JCP can further provide atransparent polyester cover strip with an integral low or highcoercivity magnetic strip with a polyester adhesive coating on one sidethat can be applied directly to a core and bonded to a core by heat andpressure. Other bonding systems/steps can be used. The magnetic strip islocated on the inner side of the polyester material which is only abouttwenty-five microns in thickness. The higher coercivity costs slightlymore to provide but strongly resists demagnetization includinginadvertent demagnetization by security devices commonly found in retailstores used to erase data on magnetic security devices adhered toproducts being sold.

The microvoided sheet material is superior to non-voided materials usedin all other known examples of encasing RFID transponder assemblies inplastic tags because the material readily collapses over the assemblieswhen the individual sheet products are heated and pressed to laminatethem without damage to the assemblies. Prior individual printed sheetproducts with just printed codes or printed code and magnetic stripetypically used the microvoided sheet product in a single layer ten milsthick for sufficient rigidity and resilience. Double sheet constructionslike products 1010 a, 1110 a, 1210 a and 1310 a were made using sevenmil thick Teslin®. The presence of the aforesaid RFID transponderassemblies in these individual sheet products with two core strips couldnot be felt, the microvoided material essentially collapsing andpossibly flowing around the assemblies where the assemblies were presentbetween the sheets. In contrast, when bonded between sheets ofconventional polymer card stock such as PVC or polyester, which lacknatural voids, a cavity has to be made to receive the RFID assembly or alump is created when the sheet(s) are(is) bonded to the RFID assembly.The microvoided sheet products further bond together better than theconventional polymer sheet stock it is believed because the adhesivepenetrates the porous sheet better than the conventional polymer cardsheet stock, which is essentially without voids. The same is true forthe outer protective polyester cover sheets and the magnetic stripematerial if applied directly to the microvoided core material. Finally,the microvoided products are “softer” and less brittle. As a resultindividual removable identification elements, particularly cards andtags, tend not to peel, crack of break like conventional PVC cards. Theclosed perimeter provided in the various tags disclosed above do notrequire reinforcement as would similar openings through the conventionalPVC material. Furthermore, this softer material transfers less pressureand stress to the transponder assemblies 27 when the removableidentification elements are flexed during normal use.

The present application relates to another method of fabricating theaforesaid RFID planar elements. It has been found possible to print bysilk screen, electrically conductive inks/toners on at least onemicrovoided polymer plastic, the aforesaid Teslin® microvoidedpolysilicate thermoplastic material. More particularly, at least theantenna portions of RFID transponder assemblies can be printed leavingonly the transponder chip to be obtained from an outside source andapplied. Chips can be obtained from the previously identifiedmanufactures and applied automatically with “pick and place” equipmentnow commercially available from different manufacturers and /ordistributors including but not limited to Mulbauer, a German companywith a place of business in Newport News, Va. Mulbauer models TAL 4000,TMA 6000 and FCM 6000 can be considered to perform this task. Theability to silkscreen inkstoners directly on a microvoided polymermaterial like Teslin® makes manufacture of the planar ID elements(cards, tags, labels) easier. The preexisting antenna designs andgeometries supplied by RFID assembly suppliers do not always fit thedesired geometry of the ID element or where they do fit, they are inrelatively tight registration. Even slight misalignment can result inthe die cutting of an RFID assembly or its antenna when the individualID elements are cut from larger sheets they are made in. Being able toprint antennas provides manufacturing flexibility for antenna layout anddesign including size, shape and frequency characteristics andscheduling because end users will no longer have to await the supply ofassemblies by manufacturers, where significant delays have occurred.Furthermore, the technique of applying an entire RFID assemblypreviously described utilizes a bed of wet glue on the substrate toreceive and hold the assembly.

FIG. 29 depicts a plurality of exemplary antenna 29 a printed withconductive ink on a first major planar side of a first flexible,preferably microvoided thermoplastic substrate sheet 1318. An RFIDprinted circuit chip 29 b (in phantom) is placed a first major planar onthe sheet 1318. Preferably a first major outer side of a operativelycoupled with the printed antenna 29 aof a first side of the secondflexible polymer plastic sheet 1320, more preferably a microvoidedthermoplastic sheet, is permanently and integrating attached to thefirst sheet 1318 encapsulating the antenna 29 a/chip 29 b assembly toform a planar core 1412 of a planar sheet product. FIGS. 30 a-32 depictfour possible layouts for fabricating planar ID elements with RFIDassemblies. FIG. 30 a depicts a printed planar sheet product l510 with aplurality of planar printed ISO CR80 sized (about three and five eighthsby about two and three eighths inch) ID cards 1562 a et seq. withmagnetic stripes 1528 a et seq. and RFID assemblies 29 a/29 b (in shadedblock form). FIG. 30 b depicts the components of sheet product 1510 inexploded end view and includes 29 a/29 b RFID assemblies sandwichedbetween core layers 1318, 1320 permanently affixed by suitable meanssuch as adhesive layers 1319 and 1321 and transparent cover sheets 1540and 1550. The dark interior lines in FIG. 30 a depict scoring to defineeight individual, rectangular printed, radio frequency identificationsheet products 1510 a-1510 h, each with its own card element 1562 a-1562h also defined by scoring. FIG. 31 a depicts a printed planar sheetproduct 1610 with a plurality of uniformly shaped, smaller than ISO CR80sized ID tags 1662 a et seq., each with a portion of a magnetic stripe1528 a, 1528 b, an RFID assembly 29 a/29 b (in shaded block form) and aclosed perimeter or other opening 1668 therethrough, enabling attachmentof the element 1662 a, 1662 b, etc., to by receipt of a conventional keyholder key holder. FIG. 3 lb is an exploded end view of the sheetproduct 1610 showing RFID assemblies 29 a/29 b sandwiched by core strips1318, 1320 and transparent first and second cover strips 1440, 1450 andmagnetic stripes 1628 a, 1628 b. FIG. 32 depicts a printed planar sheetproduct 1710 with a plurality of sets 1790 a-1790 d, each including anISO CR80 sized ID card 1762 a-1762 d, respectively and a smaller thanISO CR80 sized tag 1763 a-1763 d, respectively, each with a portion of amagnetic stripe 1728 a, 1728 b. and an RFID assembly 29 a/29 b (inphantom block form). Sets 1790 a etc are scored out of a larger cutsheet as indicated or a continuous web printed sheet product aspreviously indicated. The exploded edge view of 1710 is essentially thesame as 1610 in FIG. 31 a except for the repositioning of magneticstripes 1728 a, 1728 b. Elements 1562, 1662, 1762, 1763 would eachinclude printing as desired, optionally including unique codes incharacter and/or bar format, and transparent sheet coverings on eitheror both major sides of the sheet material core preferably over anyprinting and encasing each RFID assembly.

FIG. 30 c depicts a variation on the constructions shown in FIGS. 30 aand 31 a. FIG. 30 c depicts the components of a sheet product 1510′ inexploded end view. Sheet product 1510′ looks exactly like sheet product1510 of FIG. 30 a but has a different interior construction. Sheetproduct 1510′ includes 29 a/29 b RFID assemblies 27 applied to a firstcore layer 1318′ formed by a first flexible substrate sheet bearing thesame number 1318′, again preferably a microvoided thermoplastic sheet1318′, which sandwiched between overlapped halves of a second, largerflexible substrate sheet 1320′, opposite halves 1320 a′ and 1320 b′ ofwhich constitute individual layers of multilayer core 1512′ that arepermanently affixed by suitable means such as adhesive layers 1319 a′and 1319 b′ to opposite sides of the first sheet 1318′. Again,transparent material cover sheets 1540 and 1550 are preferablypermanently affixed by suitable means such as adhesive layers 1321 a′and 1321 b′ to opposite outer planar sides of the second sheet 1320 andcore 1512′. Preferably, the outer sides of the halves 1320 a′, 1320 b′of the second sheet 1320′ are printed with static graphic fields 1535and/or variable data fields 1524, respectively, the latter possiblyincluding codes unique to each RFID identification element, preferablybefore the second sheet 1320 is folded over the first sheet 1318′. Thus,the printing is protected by the transparent cover sheets 1540, 1550through which the printed fields are visible, while the microvoidedsubstrate sheet(s) 1318′, 1320′ cushion and protect the circuiting 27(29 a/29 b).

FIGS. 33 a depicts an exemplary RFID assembly 1827 including an antenna1829 aformed of extremely fine copper wire 1828 applied directly to afirst major planar side of a first polymer plastic, preferablymicrovoided thermoplastic substrate sheet 1318, preferably around anRFID printed circuit chip 1829 b on a holder 1829 c spanning the ends ofthe wire 1828 forming the antenna 1829 a. Chip 1829 b is preferablypreviously affixed to the same first major planar side of the firstsheet 1318. FIG. 33 b depicts part of a printed sheet product 1810including plurality of such assemblies 1827 all mounted on firstsubstrate sheet 1318. A second polymer plastic sheet, preferably amicrovoided thermoplastic material sheet like sheet 1320 or 1320′, ispermanently attached to the first sheet 1318 encapsulating the antenna1829 a/chip 1829 b assemblies 1827 to form a flexible planar core 1812of a planar sheet product 1810. Again, transparent cover sheet(s) 1540and/or 1550 can be permanently affixed to either or both major planarsides of core 1812. Planar sheet product 1810 may take any of the formsof the sheet products 1510, 1510′, 1610, 1710, etc. of FIGS. 30 a-32 andthe individual planar identification elements thereof including but notlimited to elements having major planar sides about three and fiveeighths by two and three eighths inches or less in size and beingprovided with magnetic stripes like 1528 a et seq. and/or closedperimeter openings like 1668.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention.

1. A method of making a multilayer, integral, individual planar radiofrequency identification element comprising the steps of: providing aflexible first planar substrate sheet having opposing first and secondmajor sides; applying a first one of either a radio frequencyidentification array antenna and a radio frequency identification arrayprinted circuit chip to a first portion of the first major side of thefirst planar substrate sheet; separately applying a remaining second oneof the radio frequency identification array antenna and the radiofrequency identification array printed circuit chip to the first portionof the first major side of the first planar substrate sheet in operativeoverlying relationship and connection with the first one to form anoperative radio frequency identification array on the first portion ofthe first planar substrate sheet; folding a second portion of the firstplanar substrate sheet over and against the operative radio frequencyidentification array on the first portion of the first planar substratesheet so as to completely enclose the radio frequency identificationarray between the first and second portions; and fixedly and permanentlyjoining together the first and second portions of the first major sideof the first planar substrate sheet enclosing the applied antenna andprinted circuit chip operative radio frequency identification array toencapsulate the applied antenna and printed circuit chip operative radiofrequency identification array and form at least part of a multilayerplanar core having first and second major outer sides; scoring at leastthe planar core to define at least one multilayer, integral, individualplanar radio frequency identification element removable from the planarcore containing the operative radio frequency identification array. 2.The method of claim 1 further comprising the step of printing on thesecond major side of the first planar substrate sheet before the foldingstep.
 3. The method of claim 1 further comprising a step of printing onthe second major side of the first planar substrate sheet before a stepof fixedly and permanently applying a first cover sheet to at least thefirst major outer side of the planar core.
 4. The method of claim 2wherein the step of printing on the second major side of the firstplanar substrate sheet occurs before either applying step.
 5. The methodof claim 4 wherein the step of printing on the second major side of thefirst planar substrate sheet includes printing a unique code on thesecond major side of the first planar substrate sheet.
 6. The method ofclaim 1 wherein the scoring step further comprises scoring a closedperimeter opening through the planar core within the scoring definingthe planar radio frequency identification element containing theoperative radio frequency identification array.
 7. The method of claim 1wherein the providing step comprises providing the flexible first planarsubstrate sheet of material microvoided substantially uniformlythroughout.
 8. The method of claim 1 further comprising before thescoring step, a step of fixedly and permanently applying a first coversheet to at least the first major outer side of the core and wherein thescoring step includes scoring through the first cover sheet with thecore.
 9. The method of claim 1 wherein the providing step furthercomprises processing the flexible first planar substrate sheet to makethe sheet foldable before the folding step.
 10. A method of making amultilayer, integral, individual planar radio frequency identificationelement comprising the steps of: providing a flexible first planarsubstrate sheet having opposing first and second major sides in afoldable form; applying an operative radio frequency identificationarray on a first portion of the first planar substrate sheet; folding asecond portion of the first planar substrate sheet over and against theoperative radio frequency identification array on the first portion ofthe first planar substrate sheet so as to completely enclose theoperative radio frequency identification array between the first andsecond portions; and fixedly and permanently joining together the firstand second portions of the first major side of the first planarsubstrate sheet enclosing and encapsulating the operative radiofrequency identification array to form at least part of a multilayerplanar core having first and second major outer sides while at leastpartially collapsing the first planar substrate sheet around theoperative radio frequency identification array sufficiently so as tominimize any lump created in the multilayer planar core by the operativeradio frequency identification array; and scoring at least the planarcore to define at least one multilayer, integral, individual planarradio frequency identification element removable from the planar coreand containing the operative radio frequency identification array. 11.The method of claim 10 further comprising the step of printing on thesecond major side of the first planar substrate sheet before theapplying step.
 12. The method of claim 10 further comprising a step ofprinting on the second major side of the first planar substrate sheetbefore a step of fixedly and permanently applying a first cover sheet toat least the first major outer side of the planar core.
 13. The methodof claim 10 further comprising a step of printing on the second majorside of the first planar substrate sheet a code uniquely associated withthe operative radio frequency identification array.
 14. The method ofclaim 10 wherein the scoring step further comprises scoring a closedperimeter opening through the planar core within the scoring definingthe planar radio frequency identification element containing theoperative radio frequency identification array.
 15. The method of claim10 wherein the flexible first planar sheet is microvoided substantiallyuniformly throughout the flexible first planar sheet.
 16. A method ofmaking a multilayer, integral, individual planar radio frequencyidentification element comprising the steps of: providing a flexiblefirst planar substrate sheet having opposing first and second majorsides in a foldable form; applying a plurality of operative radiofrequency identification arrays to a first portion of the first majorside of the first planar substrate sheet; folding a second portion ofthe first planar substrate sheet over and against the plurality ofoperative radio frequency identification arrays on the first portion ofthe first planar substrate sheet so as to completely enclose each of theplurality of the radio frequency identification arrays between the firstand second portions; and fixedly and permanently joining together thefirst and second portions of the first major side of the first planarsubstrate sheet enclosing the plurality of applied radio frequencyidentification arrays to form at least part of a multilayer planar corehaving first and second major outer sides encapsulating each of theplurality of applied radio frequency identification arrays between thefirst and second portions and at least partially collapsing the firstplanar substrate sheet around each of the radio frequency identificationarrays of the plurality of arrays sufficiently so as to minimize anylump created at any of the radio frequency identification arrays; andscoring at least the planar core to define at least a plurality ofmultilayer, integral, individual planar radio frequency identificationelements removable from the planar core, each removable identificationelement containing a separate one of the plurality of operative radiofrequency identification arrays.
 17. The method of claim 16 wherein theapplying step comprises a step of transferring the plurality ofoperative radio frequency identification arrays from a carrier sheetonto the first portion of the first major side of the first planarsubstrate sheet.
 18. The method of claim 16 wherein the flexible firstplanar sheet is microvoided substantially uniformly throughout theflexible first planar sheet.